JP2021057475A - Reactor - Google Patents

Abstract

To provide a reactor which has a small filling amount of a sealing resin part and is excellent in heat dissipation property.SOLUTION: A reactor 1 includes a combination body 10 including a coil 2 and a magnetic core 3, a case 5 storing the combination body 10, an insertion member 7 stored side by side with the combination body 10 in the case, and a sealing resin part 6 that is made to fill the inside of the case. The case 5 includes a bottom part 51 and side wall parts 52. The insertion member 7 includes a tip part 70 arranged at an interval from the bottom part 51. A space formed by the combination body 10, the insertion member 7 and the case 5 includes a first region 561 provided between the bottom part 51 and the tip part 70, and a second region 562 other than the first region. The sealing resin part 6 includes a first resin part 61 that is made to fill the first region 561, and a second resin part 62 that is made to fill at least a part of the second region 562. A constituent material of the insertion member 7 has type A durometer hardness of 50 or more.SELECTED DRAWING: Figure 2

Description

This disclosure relates to reactors.

Patent Document 1 discloses a reactor including a coil, a magnetic core, a square box-shaped case, and a sealing resin portion. A combination of a coil and a magnetic core is housed in the case, and a sealing resin portion is filled. Hereinafter, a material containing an uncured resin that is a raw material of the sealing resin portion may be referred to as a raw material resin.

Japanese Unexamined Patent Publication No. 2013-131567

In a reactor provided with a case and a sealing resin portion, it is desired to reduce the filling amount of the sealing resin portion. Further, a reactor having excellent heat dissipation is desirable.

The reactor described in Patent Document 1 has excellent heat dissipation because the sealing resin portion covers the periphery of the union. The reason for this is that the sealing resin portion transfers the heat of the union to the case. However, since the sealing resin portion surrounds the entire circumference of the union, the filling amount of the sealing resin portion is large. When the filling amount is large, the filling time of the raw material resin becomes long. In particular, when there is a place where the distance between the union and the case is narrow, for example, a place of 1 mm or less in order to improve heat dissipation, it is difficult for the raw material resin to flow in this narrow place. As a result, the filling time tends to be longer. If the filling time is short and there are unfilled parts, the heat dissipation will vary. Further, when the viscosity of the raw material resin is high, the raw material resin is more difficult to flow in the narrow space, and the filling time tends to be longer. From these points, there is room for improvement in terms of improving manufacturability.

Therefore, one of the purposes of the present disclosure is to provide a reactor having a small filling amount of the sealing resin portion and excellent heat dissipation.

The reactor of this disclosure is
A combination containing a coil and a magnetic core,
The case where the union is stored and
An insertion member that is stored side by side with the union in the case,
It is provided with a sealing resin portion to be filled in the case.
The case includes a bottom and a side wall.
The insertion member comprises a tip that is spaced apart from the bottom.
The space formed by the union, the insertion member, and the case includes a first region provided between the bottom portion and the tip portion, and a second region other than the first region.
The sealing resin portion includes a first resin portion filled in the first region and a second resin portion filled in at least a part of the second region.
The constituent material of the insertion member has a type A durometer hardness of 50 or more.

The reactor of the present disclosure has a small amount of filling of the sealing resin portion and is excellent in heat dissipation.

FIG. 1 is a plan view of the reactor of the first embodiment in a plan view in the depth direction of the case. FIG. 2 is a partial cross-sectional view of the reactor shown in FIG. 1 cut along the II-II cutting line. FIG. 3 is a diagram for explaining the manufacturing process of the reactor of the first embodiment, and shows a state in which the union is housed in the case. FIG. 4A is a partial cross-sectional view illustrating the manufacturing process of the reactor of the first embodiment, and shows a state in which the raw material resin is filled in the case. FIG. 4B is a plan view illustrating the manufacturing process of the reactor of the first embodiment, and shows a state in which the raw material resin is filled in the case. FIG. 5 is a diagram for explaining the manufacturing process of the reactor of the first embodiment, and shows a state in which the inserting member presses the raw material resin filled in the first region in the case. FIG. 6 is a front view showing another example of the insertion member provided in the reactor of the first embodiment.

[Explanation of Embodiments of the present disclosure]
First, the contents of the embodiments of the present disclosure will be listed and described.
(1) The reactor according to one aspect of the present disclosure is
A combination containing a coil and a magnetic core,
The case where the union is stored and
An insertion member that is stored side by side with the union in the case,
It is provided with a sealing resin portion to be filled in the case.
The case includes a bottom and a side wall.
The insertion member comprises a tip that is spaced apart from the bottom.
The space formed by the union, the insertion member, and the case includes a first region provided between the bottom portion and the tip portion, and a second region other than the first region.
The sealing resin portion includes a first resin portion filled in the first region and a second resin portion filled in at least a part of the second region.
The constituent material of the insertion member has a type A durometer hardness of 50 or more.

In the reactor of the present disclosure, the filling amount of the sealing resin portion corresponding to the volume of the insertion member can be omitted, so that the filling amount of the sealing resin portion is small. The reactor of the present disclosure is also excellent in heat dissipation. The reason for this is that at least a part of the second resin part is filled between the union and the case to cover at least a part of the union, so that the heat of the union is transferred to the case by the second resin part. Because. When there is a place where the distance between the union body and the case is narrow, for example, a place of 1 mm or less, the heat of the union body can be easily transferred to the case, and the heat dissipation is further improved.

Further, the reactor of the present disclosure can shorten the time for filling the material containing the unsolidified resin which is the raw material of the sealing resin portion, that is, the raw material resin for the following reasons (A) to (C), and thus the manufacturability. Also excellent.

(A) The amount of the raw material resin filled in the case may be smaller than that in the case where the insertion member is not provided.

(B) In the manufacturing process of the reactor, the raw material resin can be filled in a relatively large part of the space provided in the case.
Specifically, in a state where the union is stored in the case and the insertion member is not stored, the space inside the case is narrow where the insertion member has a size that can be arranged and around the union. Can have a location. The former portion can be set larger than the narrow portion depending on the size of the insertion member. If the raw material resin is filled in such a relatively large portion, the filling time tends to be shorter than in the case of filling the raw material resin in the narrow portion. Further, a nozzle for filling the raw material resin can be arranged in the relatively large portion. That is, the nozzle can be used for filling the raw material resin. At least a part of the raw material resin filled in the relatively large portion constitutes the first resin part after solidification.

(C) The raw material resin filled in the above-mentioned relatively large portion can be pressed by the inserting member. The reason for this is that the insertion member has a predetermined hardness.
The pressed raw material resin flows from the insertion member side to the union side in the case and enters the above-mentioned narrow portion. By using the insertion member as a pressurizing member for the raw material resin in this way, the raw material resin can satisfactorily flow into the narrow place even when the distance between the union and the case is narrow, for example, 1 mm or less. Can cover the union.

By pressing the raw material resin described above, the portion not filled with the raw material resin is reduced even in the narrow portion described above or when the viscosity of the raw material resin is higher. From this point as well, the reactor of the present disclosure is excellent in heat dissipation.

(2) As an example of the reactor of the present disclosure,
Examples of the constituent material include a resin or rubber.

The above-mentioned form is excellent in electrical insulation between the union and the insertion member and is lightweight as compared with the case where the constituent material is a metal. Further, in particular, the rubber insertion member is more likely to be elastically deformed than the metal insertion member, and thus easily follows the shape of the storage space of the insertion member in the space inside the case. Therefore, the rubber insertion member easily presses the raw material resin.

(3) As an example of the reactor of (2) above,
The constituent material of the tip portion is the rubber.
The tip portion includes an end face in contact with the first resin portion.
In the state where the tip portion is not elastically deformed, the area of the end face may be equal to or larger than the maximum flat area of the first region.

In the above embodiment, in the process of manufacturing the reactor, the rubber tip can press the raw material resin filled in the relatively large portion described above in a state close to liquid tightness. The pressed raw material resin easily enters even in the above-mentioned narrow space.

(4) As an example of the reactor of the present disclosure,
The length of the insertion member along the depth direction of the case may be 40% or more of the depth of the case.

In the above embodiment, since the volume of the insertion member is large, the filling amount of the raw material resin does not have to be smaller.

(5) As an example of the reactor of the present disclosure,
Examples of the constituent material of the sealing resin portion include a resin and a powder made of a non-metallic inorganic material.

In the above form, the sealing resin portion is excellent in thermal conductivity due to the powder, so that it is excellent in heat dissipation. Further, in the above-described form, even when the viscosity of the raw material resin is high due to the inclusion of the powder in the reactor manufacturing process, if the raw material resin is pressed by the insertion member as described above, the raw material resin can be pressed even in the narrow portion described above. Can be filled.

[Details of Embodiments of the present disclosure]
Hereinafter, specific examples of the reactor according to the embodiment of the present disclosure will be described with reference to the drawings. The same reference numerals in the figures indicate the same names.

[Embodiment 1]
The reactor of the first embodiment will be described with reference to FIGS. 1 to 5.
FIG. 2 is a partial cross-sectional view of the reactor 1 shown in FIG. 1 cut in a plane parallel to the depth direction of the case 5 and the case 5 and the sealing resin portion 6 are cut. The union body 10 and the insertion member 7 in FIG. 2 show an appearance, not a cross section.

(Overview)
As shown in FIG. 2, the reactor 1 of the first embodiment includes a combination body 10 including a coil 2 and a magnetic core 3, a case 5, a sealing resin portion 6, and an insertion member 7. The case 5 is a container provided with a bottom portion 51 and a side wall portion 52, and houses the union body 10 and the insertion member 7. The sealing resin portion 6 is filled in the case 5.

In particular, in the reactor 1 of the first embodiment, the union body 10 and the insertion member 7 are housed in the case 5 side by side in a direction orthogonal to the depth direction of the case 5. The insertion member 7 includes a tip 70 that is spaced apart from the bottom 51 of the case 5. The sealing resin portion 6 includes a first resin portion 61 that is filled between the bottom portion 51 and the tip portion 70. Further, the sealing resin portion 6 is also filled in a region other than the region in which the first resin portion 61 is filled in the case 5.

The insertion member 7 contributes to reducing the filling amount of the sealing resin portion 6. Further, the constituent material of the insertion member 7 has a specific hardness, which will be described later. Therefore, in the manufacturing process of the reactor 1, the insertion member 7 presses the raw material resin 600 (FIG. 5) filled in the case 5, that is, the material containing the uncured resin that is the raw material of the sealing resin portion 6. Can be used for. As a result, the insertion member 7 contributes to shortening the filling time of the raw material resin 600.

Hereinafter, with reference to FIG. 2, the outline of the union body 10, the case 5, and the sealing resin portion 6 will be described in order, and then the details of the insertion member 7 and the sealing resin portion 6 will be described in order.
The depth direction of the case 5 is the direction orthogonal to the paper surface in FIGS. 1 and 4B, and the vertical direction in the other drawings.
The direction orthogonal to the depth direction of the case 5 is, for example, the left-right direction in FIGS. 1 to 5.

(Union)
The union body 10 includes a coil 2 and a magnetic core 3. In addition, the union body 10 may include a member or the like that enhances the electrical insulation between the coil 2 and the magnetic core 3. Examples of such a member include a holding member 4 and a resin mold portion 8 which will be described later.

<coil>
The coil 2 includes a tubular winding portion formed by spirally winding the winding. An external device such as a power supply is connected to the end of the winding that is continuous with the winding portion. The winding, the end of the winding, and the external device are not shown.

Examples of the winding include a coated wire having a conductor wire and an insulating coating covering the outer periphery of the conductor wire. Examples of the constituent material of the conductor wire include copper and the like. Examples of the constituent material of the insulating coating include resins such as polyamide-imide. The winding of this example is a covered flat wire having a rectangular cross section.

The coil 2 of this example includes two winding portions 21 and 22 and a connecting portion connecting both winding portions 21 and 22. The connecting portion is not shown. Both winding portions 21 and 22 are arranged so that their axes are parallel to each other. In this example, the specifications such as the shape, winding direction, number of turns, and winding size of the winding portions 21 and 22 are the same. Further, the coil 2 of this example is composed of one continuous winding. The connecting portion is composed of a part of the winding wound between the winding portions 21 and 22.

The winding portions 21 and 22 of this example are square tubular edgewise coils. In this case, the outer peripheral surfaces of the winding portions 21 and 22 tend to be flat rectangular flat surfaces. As a result, the outer peripheral surfaces of the winding portions 21 and 22 and the inner peripheral surface 520 of the case 5 face each other in a plane. Therefore, it is easy to adjust the distance between the winding portions 21 and 22 and the inner peripheral surface 520 of the case 5.

The shape, size, etc. of the coil 2 can be changed as appropriate. Regarding this point, it is advisable to refer to the modified example 4 described later.

<Magnetic core>
The magnetic core 3 has a portion arranged inside the winding portions 21 and 22 of the coil 2 and a portion arranged outside the winding portions 21 and 22, and provides a closed magnetic path through which the magnetic flux created by the coil 2 passes. Configure.

The magnetic core 3 of this example includes four columnar core pieces. The two core pieces are inner core portions 31 and 32 having portions arranged in the winding portions 21 and 22, respectively. The remaining two core pieces are outer core portions 33 constituting a portion arranged outside the winding portions 21 and 22. The two outer core portions 33 sandwich the two inner core portions 31, 32 that are arranged apart from each other.

In this example, the core pieces constituting the inner core portions 31 and 32 have the same shape and the same size. Each core piece has a rectangular parallelepiped shape that roughly corresponds to the inner peripheral shape of the winding portions 21 and 22. Further, each core piece is an integral body and is not divided.

In this example, the core pieces constituting each outer core portion 33 have the same shape and the same size. Each core piece has a rectangular parallelepiped shape, but the shape of the core piece is not particularly limited. Further, each core piece is an integral body and is not divided.

Examples of the core piece constituting the magnetic core 3 include a molded body mainly made of a soft magnetic material. The soft magnetic material may be metal or non-metal. Examples of the metal include iron and iron-based alloys. Examples of the iron-based alloy include Fe-Si alloys and Fe-Ni alloys. Examples of the non-metal include ferrite and the like. Examples of the molded body include a molded body made of a composite material, a powder compacted body, a laminate of plate materials made of a soft magnetic material such as an electromagnetic steel plate, and a sintered body such as a ferrite core.

The composite molded article contains a magnetic powder and a resin. The magnetic powder is dispersed in the resin. Examples of the resin include thermoplastic resins and thermosetting resins. The thermoplastic resin is, for example, a polyphenylene sulfide (PPS) resin, a polytetrafluoroethylene (PTFE) resin, a liquid crystal polymer (LCP), a polyamide (PA) resin such as nylon 6 or nylon 66, a polybutylene terephthalate (PBT) resin, or an acrylonitrile. -Examples include butadiene-styrene (ABS) resin. Examples of the thermosetting resin include unsaturated polyester resin, epoxy resin, urethane resin, and silicone resin. The molded body of the composite material is typically a molded body formed by injection molding or the like.

The powder compact is an aggregate of magnetic powder. A typical example of the compaction compact is one obtained by compression molding a mixed powder containing a magnetic powder and a binder and then heat-treating it.

Examples of the powder particles constituting the above-mentioned magnetic powder include magnetic particles made of a soft magnetic material and coated particles having an insulating coating on the outer periphery of the magnetic particles.

When the magnetic core 3 includes a plurality of core pieces, the constituent materials of all the core pieces may be the same, or the constituent materials of some core pieces may be different. For example, as in this example, the magnetic core 3 may include a core piece made of a molded body of a composite material and a core piece made of a powder compact. Alternatively, all the core pieces are molded bodies of composite materials, and the type of soft magnetic material and the content of magnetic powder of each core piece are different.

In addition, the magnetic core 3 shown in FIG. 2 does not have a magnetic gap between the core pieces, but may have a magnetic gap. The magnetic gap may be an air gap, a plate material made of a non-magnetic material such as alumina, or the like. The magnetic core 3 having no magnetic gap tends to be small.

The shape, size, number of core pieces, and the like of the magnetic core 3 can be changed as appropriate. Regarding this point, it is advisable to refer to the modified example 5 described later.

<Holding member>
The reactor 1 may include a holding member 4 arranged between the coil 2 and the magnetic core 3. The holding member 4 of this example supports the winding portions 21 and 22, the inner core portions 31, 32 and the outer core portion 33, and the inner core portions 31, 32 and the outer core portion with respect to the winding portions 21 and 22. Position 33. 1 to 5 show an outline of the holding member 4, and detailed illustration will be omitted.

The holding member 4 of this example is a frame-shaped member arranged at each end of the winding portions 21 and 22. Each holding member 4 includes a frame plate provided with a pair of through holes and a peripheral wall 43 provided along the peripheral edge of the frame plate. The basic configuration of each holding member 4 is the same.

The frame plate of the holding member 4 is arranged between the end faces of the winding portions 21 and 22 and the inner end faces of the outer core portion 33. The ends of the inner core portions 31 and 32 are inserted into the through holes provided in the frame plate, respectively. Further, the frame plate includes a projecting piece. The projecting piece projects along the axial direction of the inner core portions 31 and 32 from the inner peripheral edge of the through hole on the surface of the frame plate on the winding portion 21 and 22 side. Further, the projecting piece is inserted between the inner peripheral surface of the winding portions 21 and 22 and the outer peripheral surface of the inner core portions 31 and 32. The projecting pieces separate the winding portions 21 and 22 from the inner core portions 31 and 32, and the electrical insulation between the two is enhanced. In addition, both are positioned by the projecting pieces.

The peripheral wall 43 of the holding member 4 surrounds the outer peripheral surface of the outer core portion 33, and positions the outer core portion 33 with respect to the holding member 4. The peripheral wall 43 of this example has a rectangular frame shape that continuously covers the outer peripheral surface of the outer core portion 33, that is, the surface of the side wall portion 52 of the case 5 facing the inner peripheral surface 520 (FIG. 1).

The shape, size, and the like of the holding member 4 can be changed as appropriate. A known configuration may be used for the holding member 4.

Examples of the constituent material of the holding member 4 include an electrically insulating material such as resin. For example, a thermoplastic resin and a thermosetting resin can be mentioned. For specific examples of the thermoplastic resin and the thermosetting resin, it is advisable to refer to the description of the molded body of the composite material in the section of <Magnetic Core>. The holding member 4 can be manufactured by a known molding method such as injection molding.

<Resin mold part>
The reactor 1 may include a resin mold portion 8 that covers at least a part of the magnetic core 3. The resin mold portion 8 improves the electrical insulation between the peripheral parts of the coil 2 or the reactor 1 and the magnetic core 3, and also protects the magnetic core 3 from the external environment, mechanically protects the magnetic core 3, and the like.

When the resin mold portion 8 covers the magnetic core 3 and is exposed without covering the outer peripheral surfaces of the winding portions 21 and 22, as in this example, the resin mold portion 8 is excellent in heat dissipation. The reason for this is that the outer peripheral surfaces of the winding portions 21 and 22 can be brought close to the inner peripheral surface 520 of the case 5. The resin mold portion 8 may cover both the coil 2 and the magnetic core 3.

The covering range, thickness, etc. of the resin mold portion 8 can be appropriately selected.
The resin mold portion 8 of this example includes inner resin portions 81 and 82 and an outer resin portion 83. The inner resin portions 81 and 82 cover at least a part of the inner core portions 31 and 32, respectively. The outer resin portion 83 covers at least a part of each outer core portion 33. In this example, the inner resin portions 81 and 82 and the outer resin portion 83 are continuous integrally molded products. Such a resin mold portion 8 integrally holds a plurality of core pieces to increase the strength and rigidity of the magnetic core 3 as an integral body.

In addition, the resin mold portion 8 may not include, for example, the inner resin portions 81 and 82, and may substantially cover only the outer core portion 33.

Examples of the constituent material of the resin mold portion 8 include various resins. For example, a thermoplastic resin can be mentioned. For specific examples of the thermoplastic resin, it is advisable to refer to the description of the molded body of the composite material in the section of <Magnetic Core>. In addition to the resin, the constituent material may contain a powder made of a non-metallic inorganic material described in the section (sealing resin portion) described later. The resin mold portion 8 containing this powder is excellent in heat dissipation. A known molding method such as injection molding can be used for molding the resin mold portion 8.

(Case)
In the case 5, substantially the entire union body 10 is housed, and the union body 10 is protected from the external environment, mechanically protected, and the like. The case 5 of this example is made of metal and also functions as a heat dissipation path of the union body 10.

The case 5 is a bottomed tubular body composed of a bottom portion 51 and a side wall portion 52. In case 5, the side opposite to the bottom 51 and the upper side in FIG. 2 are open. The bottom portion 51 is a flat plate-shaped member. The side wall portion 52 is a frame-shaped member that is erected from the peripheral edge of the bottom portion 51 and is continuous with the peripheral edge. The bottom portion 51 and the side wall portion 52 form an internal space having a shape and size capable of accommodating the union body 10 and the insertion member 7.

The case 5 of this example is a rectangular parallelepiped container, and has a rectangular parallelepiped internal space that roughly corresponds to the shape of the opening. The opening is rectangular in plan view from the depth direction of the case 5 (FIG. 1). Specifically, of the four corners of the rectangle, the corner on one end side in the long side direction is rounded, and the other end side is angular (FIG. 1). The long side direction of the rectangle is the left-right direction in FIG. 1, and one end side in the long side direction is the left side. The short side direction of the rectangle is the vertical direction in FIG.

The side wall portion 52 has a square tubular shape. The inner peripheral surface 520 of the side wall portion 52 has a first surface 521 and a second surface 522 facing each other, and a third surface 523 and a fourth surface 524 facing each other (FIG. 1). The first surface 521 and the second surface 522 are located on both sides in the long side direction described above. The third surface 523 and the fourth surface 524 are located on both sides in the short side direction described above. The second surface 522 to the fourth surface 524 are all flat surfaces. The first surface 521 includes curved surfaces at the connection points with the third surface 523 and the connection points with the fourth surface 524, and is otherwise flat.

The size of the internal space of the case 5 is adjusted so that the sealing resin portion 6 having a predetermined size is provided in the case 5 in which the union body 10 and the insertion member 7 are housed. Here, the space created by the union body 10, the insertion member 7, and the case 5 is other than the first region 561 provided between the bottom portion 51 of the case 5 and the tip portion 70 of the insertion member 7, and the first region 561. It includes a second region 562. In FIG. 2 and the like, the first region 561 and the second region 562 are shown as virtual regions. The first region 561 and at least a part of the second region 562 are filled with the sealing resin portion 6. The size of the internal space of the case 5 depends on the size of the union body 10 and the insertion member 7 so that the sealing resin portion 6 filled in the first region 561 and the second region 562 has a predetermined size. Is adjusted.

The first region 561 is mainly surrounded by the inner bottom surface of the bottom portion 51 of the case 5, the inner peripheral surface 520 of the case 5, the outer peripheral surface 100 of the union body 10, and the end surface 71 of the tip end portion 70 of the insertion member 7. The area. In this example, the first region 561 is provided in the case 5 on one end side and the bottom 51 side in the long side direction described above. Therefore, the inner peripheral surface 520 constituting the first region 561 is the first surface 521 located on one end side in the long side direction described above. Further, the outer peripheral surface 100 constituting the first region 561 is an outer peripheral surface of the peripheral wall 43 of the holding member 4 arranged on the bottom 51 side, and is a surface facing the first surface 521, which is the left side surface in FIG. ..

_{In the first region 561, the height H 6} from the inner bottom surface of the bottom portion 51 of the case 5 to the end surface 71 of the tip portion 70 of the insertion member 7 is filled in the first region 561 of the sealing resin portion 6. It corresponds to the height of one resin portion 61. The height H ₆ is a length along the depth direction of the case 5.

The second region 562 of this example is mainly a region surrounded by the inner bottom surface of the bottom portion 51 of the case 5, the inner peripheral surface 520 of the case 5, and the outer peripheral surface 100 of the union body 10, and is the first region 561. This is the area excluding. In this example, the inner peripheral surface 520 constituting the second region 562 is the second surface 522 to the fourth surface 524. Further, the outer peripheral surface 100 constituting the second region 562 is a portion of the outer peripheral surface 100 of the union body 10 excluding the surface facing the first surface 521, that is, the left side surface in FIG.

In the second region 562, the distance between the outer peripheral surface 100 of the union body 10 and the inner peripheral surface 520 of the case 5, here the second surface 522 to the fourth surface 524, is the union of the sealing resin portions 6. corresponds to the thickness t ₆ of the second resin portion 62 described later which surrounds the outer peripheral surface 100 of the body 10. As shown in FIG. 1, the thickness t ₆ is the length along the long side direction of the case 5 or the length along the short side direction.

In the internal space of the case 5, the length L ₅ along the long side direction described above is substantially equal to the total length of the length L ₁₀ , the length L _7, and the thickness t _6. The length L ₁₀ is the length of the union 10 along the long side direction. The length L ₇ is the maximum distance from the outer peripheral surface 100 of the union body 10, here, the outer peripheral surface of the peripheral wall 43 of the holding member 4 to the first surface 521.

_{The depth H 5} of the case 5 is equal to _{or higher than the height H 10} (FIG. 3) along the axial direction of the winding portions 21 and 22 in the union body 10. In this example, the depth H ₅ is slightly larger than the height H _10.

The case 5 of this example is a metal box in which the bottom portion 51 and the side wall portion 52 are integrally formed. In particular, when the metal constituting the case 5 is an aluminum-based material as in this example, the case 5 is a lightweight, non-magnetic material having excellent heat dissipation, so that it is unlikely to have a magnetic effect on the coil 2. It has the effect of. The aluminum-based material is pure aluminum or an aluminum-based alloy.

(Encapsulating resin part)
The sealing resin portion 6 is filled in at least a part of the space formed by the union body 10, the insertion member 7, and the case 5. Further, the sealing resin portion 6 covers at least a part of the union body 10 in the case 5 and is in contact with at least a part of the insertion member 7. The sealing resin portion 6 protects the union 10 from the external environment, mechanically protects the union 10, improves the electrical insulation between the union 10 and the case 5, and integrates the union 10 and the case 5. , Has functions such as improving heat dissipation.

The sealing resin portion 6 of this example is filled in substantially all of the above-mentioned space. That is, the sealing resin portion 6 buries substantially the entire union body 10 and substantially the entire insertion member 7.

Examples of the constituent material of the sealing resin portion 6 include various resins. For example, a thermosetting resin can be mentioned. Examples of the thermosetting resin include silicone resin, epoxy resin, urethane resin, unsaturated polyester resin and the like. The sealing resin portion 6 mainly composed of a silicone resin is excellent in heat resistance and heat dissipation. The silicone resin may be in the form of a gel. The sealing resin portion 6 mainly composed of epoxy resin has a high elastic modulus, and the combined body 10 can be firmly fixed to the case 5. Examples of other resins include thermoplastic resins such as PPS resin.

As in this example, the constituent material of the sealing resin portion 6 may include the above-mentioned resin and a powder made of a non-metallic inorganic material. Examples of the non-metallic inorganic material include ceramics and carbon-based materials. Examples of ceramics include alumina and silica. Such a non-metallic inorganic material is superior in thermal conductivity to the above resin. Therefore, the sealing resin portion 6 containing the powder made of the non-metal inorganic material, particularly the powder made of the non-metal inorganic material having a high thermal conductivity, can transfer the heat of the union 10 to the case 5 well. For example, the thermal conductivity of the sealing resin portion 6 is 1 W / m · K or more, and further 1.5 W / m · K or more. The sealing resin portion 6 containing the powder made of ceramics is also excellent in electrical insulation. In addition, a known resin composition may be used as the constituent material of the sealing resin portion 6.

(Insert member)
<Overview>
The insertion member 7 is a member independent of the union body 10, the case 5, and the sealing resin portion 6. However, the insertion member 7 is housed in the case 5 along with the union body 10. Typically, the insertion member 7 is a columnar or rod-shaped member having a length H _{7 less than the depth H 5} of the case 5, and as in this example, the case 5 is along the depth direction of the case 5. It is stored inside.

Further, in the state of being housed in the case 5, at least a part of the insertion member 7 is in contact with the sealing resin portion 6. Specifically, the tip 70 of the insertion member 7 arranged on the bottom 51 side of the case 5 is in contact with the first resin portion 61 of the sealing resin 6 which is filled on the bottom 51 side. It can be said that the insertion member 7 provided with such a tip portion 70 was in contact with the raw material resin 600 of the sealing resin portion 6 filled on the bottom portion 51 side of the case 5 in the manufacturing process of the reactor 1.

In addition, in this example, another part of the insertion member 7 is in contact with the outer peripheral surface 100 of the union body 10. Further, another part of the insertion member 7 is in contact with a part of the inner peripheral surface 520 of the case 5. Specifically, the insertion member 7 is in contact with the outer peripheral surface of the peripheral wall 43 of the holding member 4 arranged on the opening side of the case 5 at the end portion arranged on the opposite side of the tip portion 70, that is, on the opening side of the case 5. A portion and a portion in contact with the first surface 521 of the case 5 are provided. So to speak, the end portion of the insertion member 7 is sandwiched between the peripheral wall 43 of the union body 10 and the first surface 521 of the case 5.

The insertion member 7 of this example is a columnar body made of a single material, here rubber. Further, the insertion member 7 of this example is a medium entity having a cross-sectional shape and a cross-sectional area cut in a plane orthogonal to the axial direction of the insertion member 7 having a uniform shape and a uniform size in the axial direction.

<Hardness of constituent materials>
The constituent material of the insertion member 7 has a type A durometer hardness of 50 or more. When the type A durometer hardness is 50 or more, it can be said that the insertion member 7 has a hardness that can be pressed even if the above-mentioned raw material resin 600 has a high viscosity in the manufacturing process of the reactor 1. The higher the hardness of the Type A durometer, the more rigid the insertion member 7 is, and the easier it is to press the raw material resin 600. From this point, the type A durometer hardness may be 60 or more and 70 or more.

The hardness of the constituent material of the insertion member 7 may be a hardness exceeding the measurement range of the type A durometer hardness, for example, a type D durometer hardness. For example, the type D durometer hardness of the constituent material may be 80 or more or 100 or more. Alternatively, the hardness of the constituent material may be a hardness that can measure Vickers hardness. For example, the Vickers hardness of the constituent material may be 50 or more or 80 or more. For all hardness measurements, a commercially available measuring device may be used.

On the other hand, the type A durometer hardness may be 90 or less, and further 85 or less. In this case, the insertion member 7 is excellent in elastic deformability. Therefore, even if the size of the insertion member 7 in the non-elastically deformed state is larger than the size of the storage location of the insertion member 7 in the case 5, for example, if the insertion member 7 is elastically deformed, it can be arranged at the storage location. Can be done. That is, the insertion member 7 easily follows the shape of the storage portion.

<Composition of constituent materials>
The constituent material of the insertion member 7 may be an electrically insulating material or a conductive material as long as it satisfies the above-mentioned specific hardness. Of the insertion members 7, at least the constituent material of the surface layer at a position close to the coil 2, the magnetic core 3, and the case 5 is preferably an electrically insulating material. The reason for this is that the electrical insulation between the insertion member 7 and the coil 2 and the like described above is excellent.

Examples of the electrical insulating material include resins, rubbers, and ceramics. Examples of the conductive material include metals and carbon-based materials. In addition, the constituent material may be a mixture of an electrically insulating material and a conductive material.

If the constituent material of the insertion member 7 is resin or rubber, the electrical insulation between the insertion member 7 and the coil 2, the magnetic core 3, and the case 5 is enhanced. Further, in this case, the insertion member 7 is lighter than the case where the constituent material contains metal. In addition to the resin or rubber, the constituent material may contain a powder made of the non-metallic inorganic material described in the above section (sealing resin portion). In this case, the insertion member 7 has excellent thermal conductivity as described above, and easily transfers the heat of the union body 10 to the case 5.

"resin"
Specific examples of the resin include a thermoplastic resin and a thermosetting resin. For specific examples of the thermoplastic resin and the thermosetting resin, it is advisable to refer to the description of the molded body of the composite material in the section of <Magnetic Core>. Resin is generally superior in rigidity to rubber. Therefore, the insertion member 7 whose constituent material is resin is more likely to press the raw material resin 600 in the manufacturing process of the reactor 1 than when it is made of rubber. Some resins have Type D durometer hardness or Vickers hardness.

When the constituent material of the insertion member 7 contains a resin, this resin may be the same as the resin constituting the sealing resin portion 6. In this case, there is substantially no difference in the coefficient of thermal expansion between the insertion member 7 and the sealing resin portion 6. Therefore, it is possible to prevent cracks and the like due to thermal expansion and contraction from occurring in at least one of the insertion member 7 and the sealing resin portion 6. The resin in the insertion member 7 and the resin in the sealing resin portion 6 may be different.

When the constituent material of the insertion member 7 contains resin and the portion of the union body 10 in contact with the insertion member 7, in this example, the holding member 4 contains resin, the resin in the insertion member 7 is the same as the resin in the holding member 4. But it may be. In this case, there is substantially no difference in the coefficient of thermal expansion between the insertion member 7 and the holding member 4. Therefore, it is possible to prevent the occurrence of cracks and the like due to thermal expansion and contraction in at least one of the insertion member 7 and the holding member 4. The resin in the insertion member 7 and the resin in the holding member 4 may be different. Further, when the portion of the combined body 10 in contact with the insertion member 7 is the resin mold portion 8, the same applies to the holding member 4.

《Rubber》
Specific examples of the rubber include natural rubber, isoprene rubber, styrene-butadiene rubber, butadiene rubber and the like. In particular, rubber having a type A durometer hardness of 90 or less is excellent in elastic deformability. The insertion member 7 made of rubber having excellent elastic deformability has a high degree of freedom in size as described above. The constituent material of the insertion member 7 may be rubber having a type D durometer hardness.

《Ceramics》
For specific examples of ceramics, it is advisable to refer to the above-mentioned (sealing resin portion) section. Ceramics, metals described below, and carbon-based materials generally have Vickers hardness.

《Conductive material》
When the constituent material of the insertion member 7 includes a conductive material, the metal or carbon-based material is generally superior in thermal conductivity to resin or rubber. Therefore, the insertion member 7 whose constituent material is a metal, a carbon-based material, or the like can satisfactorily transfer the heat from the union body 10 to the case 5 and contribute to the improvement of heat dissipation.

《Others》
The constituent material of the insertion member 7 may be a single material or may include a plurality of materials. That is, the insertion member 7 may be a braid of members made of different materials. Since the insertion member 7 made of a single material as in this example is easy to mold, it is excellent in manufacturability. The insertion member 7 which is the above-mentioned assembly has characteristics according to each material. As a specific example, as shown in the modified example 1 (1) described later, there is a form (FIG. 6 described later) including a tip portion 70 made of rubber and a shaft portion 75 made of resin. Alternatively, although not shown, a form including a core made of metal and a surface layer made of an electrically insulating material can be mentioned.

<Construction>
The insertion member 7 of this example is an integrally molded product. In this case, the insertion member 7 is excellent in manufacturability. In addition, the insertion member 7 may be an assembly of a plurality of members as shown in the modified example 1 (1) described later.

The insertion member 7 of this example includes two opposing end faces 71 and 72 and an outer peripheral surface connecting both end faces 71 and 72, and has a rectangular parallelepiped shape in a state where it is not elastically deformed. In this example, the end faces 71 and 72 are flat surfaces. The outer peripheral surface includes a flat surface and a curved surface. In a state where the insertion member 7 is housed in the case 5, the end surface 71 arranged on the bottom 51 side of the case 5 and its vicinity are the tip 70 of the insertion member 7. That is, the tip portion 70 has a part of the sealing resin portion 6, here, the end face 71 in contact with the first resin portion 61.

<shape>
The insertion member 7 of this example is a columnar space 560 (columnar space 560) provided on one end side in the long side direction in the case 5 in a state where the union body 10 is housed in the case 5 and the insertion member 7 is not housed. It has a shape that roughly corresponds to the shapes shown in FIGS. 1 and 3). Specifically, the planar shapes of the end faces 71 and 72 are substantially similar to the planar shape of the space 560, and are rectangular shapes in which two of the four rectangular portions are rounded (FIG. 1). .. If the constituent material of the insertion member 7 is a material having excellent elastic deformability as in this example, the planar shape of the end faces 71 and 72 is a shape dissimilar to the planar shape of the space 560, which is perfect here. It may be rectangular or circular.

The planar shapes of the end faces 71 and 72 are the shapes viewed in a plan view from the axial direction of the insertion member 7. The axial direction of the insertion member 7 is substantially equal to the depth direction of the case 5 when the insertion member 7 is housed in the case 5. The plane shape of the space 560 is a shape viewed in a plane from the depth direction of the case 5. In this example, the planar shape of the space 560 is mainly the outer periphery of the peripheral wall 43 of the holding member 4 among the first surface 521 located on one end side in the long side direction of the case 5 and the outer peripheral surface 100 of the union body 10. It is a surface and has a shape composed of a surface facing the first surface 521.

In this example, the outer peripheral surface of the insertion member 7 includes two curved surfaces corresponding to the rounding of the corners described above, and two side surfaces 701 and 705 arranged to face each other. Both sides 701 and 705 are flat. The shape formed by the side surface 705 and the two curved surfaces generally corresponds to the shape of the first surface 521 of the case 5. The side surface 701 is arranged to face the outer peripheral surface of the peripheral wall 43 of the holding member 4 arranged on the opening side of the case 5 in the union body 10.

<size>
The insertion member 7 preferably has a size corresponding to the size of the space 560 on one end side in the case 5 described above. One of the reasons for this is that the volume of the insertion member 7 tends to be large, the filling amount of the sealing resin portion 6, that is, the filling amount of the raw material resin 600 tends to be small, and the inserting member 7 reliably fills the raw material resin 600. This is because it can be pressed. Another reason is that the insertion member 7 can prevent the union body 10 from being displaced in the case 5.

For example, when the insertion member 7 is a columnar body as in this example, the maximum area S including the area of the cross section cut by the plane orthogonal to the axial direction of the insertion member 7 and the areas of both end faces 71 and 72. _7max the like at least 70% of the plane area _{S max} space 560. The flat area S _max of the space 560 is the maximum flat area of the space 560 where the insertion member 7 is arranged. Typically, the flat area S _max is the maximum flat area of the first region 561 described later. The flat area S _max is preferably larger than the cross-sectional area of the nozzle 9 (FIGS. 4A and 4B) described later. The reason for this is that the nozzle 9 can be inserted into the space 560.

The larger the area S _7max of the insertion member 7, the larger the volume of the insertion member 7. Therefore, the filling amount of the sealing resin portion 6 tends to be small. Therefore, the area S _7max of the insertion member 7 may be 75% or more, 80% or more, 90% or more, 95% or more of the flat area S _{max of the space 560.}

The upper limit of the area S _7max of the insertion member 7 can be appropriately selected according to the constituent materials of the insertion member 7. The insertion member 7 can be inserted viewpoint in space 560, the upper limit of the area _{S 7Max} include less than 100% of the planar area _{S max} space 560. Hard material constituting material is elastically deformed in the insertion member 7, if for example a ceramic or the like, the upper limit of the area _{S 7Max} include less than 100% of the planar area _{S max} space 560.

Material easily constituent material of the insertion member 7 is elastically deformed, if, for example, rubber or the like, the upper limit of the area S _7Max, in a state where the insertion member 7 is not elastically deformed, or 100% of the planar area S _max space 560 It may be. This is because, when placing the insertion member 7 into the space 560, of the insertion member 7, by elastically deforming a portion having the area S _7Max, inserted in the following locations plane area S _max in the space 560 members 7 Because you can insert. _{Although it depends on} the material of the rubber and the like, the area S 7max may be 105% or more, 108% or more, 110% or more of the flat area S _{max of the space 560.} The larger the area S _{7max, the} smaller the filling amount of the sealing resin portion 6 tends to be. However, if the area S _7max is too large, the frictional force is too large when the insertion member 7 is arranged in the space 560, and it is difficult to insert the insertion member 7. It is also possible that the union body 10 and the case 5 are scratched by friction. Therefore, the area S _7max of the end face 71 may be 130% or less of the flat area S _{max of the space 560.}

In this example, the constituent material of the tip portion 70 is rubber, and the area S ₇ of the end faces 71 and 72 is 100% or more of _{the flat area S max} of the space 560 in a state where the tip portion 70 is not elastically deformed. .. Since the volume of the tip portion 70 is large, the insertion member 7 of this example can easily reduce the filling amount of the sealing resin portion 6. Further, the raw material resin 600 pressed against the elastically deformed tip portion 70 easily flows from the insertion member 7 side to the combined body 10 side and from the bottom 51 side of the case 5 to the opening side. That is, the raw material resin 600 easily flows into the second region 562. In particular, even if the second region 562 has a narrow portion, the pressed raw material resin 600 easily enters the narrow portion. The reason for this is that due to the elastically deformed tip portion 70, the portion _{having the flat area S max} in the space 560 and its vicinity are in a state close to liquid-tightness filled with the raw material resin 600. The larger the area S _{7, the} easier it is to reduce the filling amount of the raw material resin 600, and the easier it is to build the above-mentioned liquid-tight state. Therefore, the area S ₇ may be 105% or more, 108% or more, or 110% or more of the flat area S _{max of the space 560.} Further, from the viewpoint of reducing friction described above, the area S ₇ may be 130% or less of the flat area S _{max of the space 560.}

In the state where the insertion member 7 of this example and the union body 10 are housed in the case 5, the elastically deformed tip 70 is located in the first region 561 on the bottom 51 side of the case 5 in the space 560. It is filled. Further, by elastically deforming, the tip portion 70 is in close contact with the first surface 521 of the case 5 and the holding member 4 on the bottom portion 51 side.

In this example, furthermore, the area S ₇ of the end faces 71 and 72, in the space 560 is a holding member 4 or the plane area near region disposed on the opening side of the case 5. Therefore, in a state where the union body 10 and the insertion member 7 are housed in the case 5, the elastically deformed insertion member 7 is filled in the region on the opening side in the space 560. Further, due to the elastic deformation, the end portion of the insertion member 7 opposite to the tip portion 70 is in close contact with the first surface 521 of the case 5 and the holding member 4 (FIG. 1). Such an insertion member 7 functions as a positioning member for the union body 10 in the case 5.

_{Further, for example, the length H 7} of the insertion member 7 along the axial direction is 40% or more of the depth H _{5 of the case 5.} If the length H ₇ is 40% or more of the depth H ₅ , the volume of the insertion member 7 tends to increase. The length H ₇ can be selected in the range of less than 100% of the depth H _{5 of the case 5.} The longer the length H ₇ of the insertion member 7, the larger the volume of the insertion member 7 tends to be. Therefore, the length H ₇ may be 45% or more, 50% or more, 55% or more, or 60% or more of the _{depth H 5.} In particular, when the area S ₇ of the end faces 71 and 72 is equal to or larger than the flat area S _max and the length H ₇ is 40% or more of the depth H ₅ , the volume of the insertion member 7 is large and preferable.

Insertion length _{H 7} members 7 to 90% of the depth _{H 5} cases 5, 85% or less, or 80% or less. In this case, it is easy to prevent the filling amount of the raw material resin 600, that is, the filling amount of the sealing resin portion 6 from becoming too small. If the length H _{7 is 90% or less of the depth H 5} of the case 5, the depth is between the end face 71 and the inner bottom surface of the bottom 51 of the case 5 when the insertion member 7 is housed in the case 5. the interval of 10% or more of _{H 5} is ensured. In this case, the reactor 1 includes a first resin portion 61 having _{a height H 6} which is 10% or more of _{the depth H 5.}

In this example, the length H ₇ of the insertion member 7 is 40% or more and 80% or less of the depth H _{5 of the case 5.} Therefore, when the insertion member 7 is housed in the case 5, the insertion member 7 does not protrude from the opening of the case 5. The length _{H 7} of the insertion member 7 is shorter than the length _{H 10} of the combined product 10.

The constituent materials, shapes, structures, sizes, etc. of the insertion member 7 can be appropriately changed. Regarding this point, it is advisable to refer to the modified example 1 described later.

(Stored in the case)
In this example, the union body 10 is housed in the case 5 so that the axial direction of the winding portions 21 and 22 is parallel to the depth direction of the case 5. The insertion member 7 is housed in the case 5 so that the axial direction of the insertion member 7 is parallel to the depth direction of the case 5. Further, the union body 10 and the insertion member 7 are housed side by side in the above-mentioned long side direction of the case 5. So to speak, the union body 10 is closer to one end side in the longitudinal direction, to the right side in FIG. The insertion member 7 is closer to the other end side in the longitudinal direction, to the left side in FIG.

In this example, the end surface 71 of the insertion member 7 faces the inner bottom surface of the bottom portion 51 of the case 5, and is arranged at a certain distance from the inner bottom surface. The distance between the end face 71 and the inner bottom surface is 20% or more and (depth H ₅ − length H ₇ ) or less of _{the depth H 5 of the case 5.} The first resin portion 61, which is a part of the sealing resin portion 6, is filled between the end face 71 and the inner bottom surface. The end face 72 of the insertion member 7 is covered with a second resin portion 62 which is another portion of the sealing resin portion 6.

In this example, the side surface 705 and the curved surface of the outer peripheral surface of the insertion member 7 are in contact with the first surface 521 of the inner peripheral surface 520 of the case 5 over substantially the entire area thereof. Further, a part of the side surface 701 of the outer peripheral surface of the insertion member 7 is in contact with the outer peripheral surface of the peripheral wall 43 of each holding member 4 in the outer peripheral surface 100 of the union body 10. That is, in the space 560, the region other than the first region 561 is generally filled with the insertion member 7, and the sealing resin portion is formed between the side surface 705 and the union body 10, here the outer peripheral surface of the winding portion 22. Part of 6 is filled.

The storage state of the union body 10 in the case 5 can be changed as appropriate. Regarding this point, it is advisable to refer to the modified example 4 described later.

(Encapsulating resin part)
The sealing resin portion 6 includes a first resin portion 61 and a second resin portion 62. The first resin portion 61 and the second resin portion 62 are continuous integrated objects.

The first resin portion 61 is filled in the first region 561 of the space 560 in the case 5. In this example, the first resin portion 61 is in surface contact with the end surface 71 of the insertion member 7.

The size of the first resin portion 61 is a size corresponding to the first region 561. That is, the first resin portion 61 has the above-mentioned flat area S _max and height H ₆ . The size along the direction perpendicular to the depth direction of the case 5 of the first resin portion 61, where the size along the long side direction of the above in the case 5 is generally the length L ₇ of the above Equivalent to.

The second resin portion 62 is filled in at least a part of the second region 562. As in this example, the second resin portion 62 preferably covers at least the winding portions 21 and 22 of the union body 10. One of the reasons for this is that the second resin portion 62 is excellent in electrical insulation between the winding portions 21 and 22 and the case 5. Another reason is that the heat of the winding portions 21 and 22 is satisfactorily transferred to the case 5 via the second resin portion 62, and the heat dissipation is excellent.

The second resin portion 62 of this example is filled over substantially the entire area of the second region 562. Therefore, the second resin portion 62 includes a portion that covers the outer peripheral surface 100 of the union body 10, and a portion that covers the opening side surface of the case 5 and the end surface 72 of the insertion member 7 in the union body 10.

_{The thinner the thickness t 6 of the} portion of the second resin portion 62 that covers the outer peripheral surface 100 of the union body 10, the smaller the filling amount of the raw material resin 600, that is, the filling amount of the sealing resin portion 6. Further, since the winding portions 21 and 22 are close to the case 5, the reactor 1 is excellent in heat dissipation. For example, the thickness t ₆ may be 1.5 mm or less, further 1 mm or less, and 0.8 mm or less. As in this example, the thickness t ₆ may be 0.5 mm or more and 1 mm or less. The thicker the thickness t _{6, the} easier it is for the sealing resin portion 6 to fix the union body 10 in the case 5.

The second resin portion 62 may expose a portion other than the winding portions 21 and 22 in the union body 10 as long as it covers the winding portions 21 and 22. For example, the second resin portion 62 may expose a region on the opening side of the case 5 in the union body 10, here, an end face of the holding member 4 and a portion of the resin mold portion 8 that covers the end face of the outer core portion 33. ..

(Reactor manufacturing method)
Reactor 1 of the embodiment can be manufactured, for example, by a method for manufacturing a reactor including the following steps.
(First step) The union body 10, the case 5, and the insertion member 7 are prepared.
(Second step) The union body 10 is stored in the case 5.
(Third step) The case 5 is filled with the raw material resin 600 of the sealing resin portion 6.
(Fourth step) The insertion member 7 is housed in the case 5 while pressing the raw material resin 600 in the case 5.

Hereinafter, a method for manufacturing a reactor including the above steps will be described mainly with reference to FIGS. 3 to 5.
The case 5, the case 4A and the raw material resin 600 shown in FIG. 3 are cross-sectional views taken along a plane parallel to the depth direction of the case 5.
The union body 10 and nozzle 9 of FIG. 4A and the union body 10 and insertion member 7 of FIG. 5 show an appearance rather than a cross section.

In the first step, the union body 10 is obtained by combining the coil 2, the magnetic core 3, and the holding member 4 in this example (FIG. 3). When the union body 10 includes the resin mold portion 8 as in this example, the resin mold portion 8 is further formed. For example, in a state where the coil 2 and the magnetic core 3 are positioned by the holding member 4, at least a part of the union body 10 is covered with the unsolidified resin which is the raw material of the resin mold portion 8 to solidify the resin.

The resin mold portion 8 of this example may be manufactured as follows, for example. The size of the peripheral wall 43 is adjusted so that a gap is provided between the inner peripheral surface of the peripheral wall 43 of the holding member 4 and the outer peripheral surface of the outer core portion 33. The space that communicates this gap, the through hole of the holding member 4, and the gap between the winding portions 21 and 22 and the inner core portions 31 and 32 is filled with the resin that is the raw material of the resin mold portion 8. Solidify.

In the second step, the union body 10 is stored in the case 5 so that the union body 10 is in a predetermined storage state. In this example, as virtually shown by the alternate long and short dash line in FIG. 3, the union body 10 is housed in the case 5 by moving it to the other end side in the long side direction of the case 5 and to the right side in FIG. As a result, before the insertion member 7 is stored, in the case 5 in which the union body 10 is stored, the first surface 521 and the outer peripheral surface of the union body 10 are on one end side in the long side direction, on the left side in FIG. A space sandwiched between the surface facing the first surface 521 in 100, that is, a space 560 is provided. The space 560 is used as a filling place for the raw material resin 600 (see FIG. 4A) and a storage place for the insertion member 7 (see FIG. 5). Of the space in the case 5 in which the above-mentioned union body 10 is housed, the area other than the space 560 is the second area 562.

In the third step, the nozzle 9 is inserted into the space 560 in the case 5, and the raw material resin 600 is filled into the space 560 from the nozzle 9 (FIG. 4A). When the liquid level of the raw material resin 600 reaches a predetermined end position in the space 560, filling is stopped. Also, the nozzle 9 is pulled out from the space 560.

As the nozzle 9, _{a cylindrical material having a diameter of L 7} (FIG. 1) or less can be used. The diameter of the nozzle 9 is, for example, 3.5 mm or more and 5 mm or less. In this case, the length L ₇ is, for example, 5 mm or more and 15 mm or less.

The tip of the nozzle 9 is arranged close to the bottom 51 of the case 5 (FIG. 4A). With this arrangement, the raw material resin 600 is filled in the space 560 from the bottom 51 toward the opening side of the case 5. In this example, since the first surface 521 of the case 5 has a curved surface, the cylindrical nozzle 9 can be arranged closer to one curved surface side of the first surface 521 (FIG. 4B). With this arrangement, when the raw material resin 600 spreads in the second region 562, the place where the raw material resin 600 joins can be set to a position away from the filling start point of the raw material resin 600, here, the position where the nozzle 9 is arranged. .. Further, in the case of the one-point casting type using one nozzle 9 as in this example, the number of the above-mentioned merging points tends to decrease. From these facts, it is difficult for the raw material resin 600 to entrain air bubbles, and it is easy to prevent the air bubbles from remaining in the sealing resin portion 6. Note that FIG. 4A illustrates a state in which the tip of the nozzle 9 is located below in the vertical direction and the nozzle 9 is arranged in the space 560 so that the axis of the nozzle 9 is along the vertical direction. The opening at the tip of the nozzle 9 opens toward the inner bottom surface of the bottom portion 51 of the case 5.

The filling amount of the raw material resin 600 may be set based on the total volume of the volume of the first region 561 and the volume of the second region 562. The end position of the liquid level described above is set according to the volume of the set filling amount and the volume of the space 560. The end position along the bottom 51 of the case 5 in the depth direction of the case 5, 70% or less of the point of the depth H _{5 (FIG.} 2), further is 60% or less at the point of the depth H _5, The filling amount of the raw material resin 600 may be small. Therefore, when the viscosity of the raw material resin 600 is high, for example, even when it is 9 P · s or more, and further 10 P · s or more, the filling time tends to be short. When the raw material resin 600 has a high viscosity, for example, it may contain a powder made of a non-metallic inorganic material as in this example.

The filling of the raw material resin 600 is a so-called casting. Further, the flat area of the space 560 is sufficiently large with respect to the diameter of the nozzle 9 (FIG. 1). Therefore, the raw material resin 600 discharged from the nozzle 9 substantially spreads only in the space 560, and hardly fills the second region 562. As a result, when the raw material resin 600 is filled in the space 560 from the nozzle 9, the liquid level of the raw material resin 600 rises only in the space 560.

If the filling operation of the raw material resin 600 is performed while evacuating in the vacuum chamber, air bubbles are less likely to remain in the sealing resin portion 6.

In the fourth step, the insertion member 7 is inserted into the space 560 from the opening side of the case 5 in the space 560 (FIG. 5). In particular, the raw material resin 600 is pressed by the insertion member 7 (FIG. 5). By this pressing, the raw material resin 600 moves to the second region 562 side. As the raw material resin 600 flows, the liquid level of the raw material resin 600 in the space 560 is displaced toward the bottom 51 side of the case 5, that is, it descends. Further, the liquid level of the raw material resin 600 in the second region 562 is displaced to the opening side, that is, rises. When the liquid level of the raw material resin 600 in the second region 562 reaches a predetermined position in the case 5 and the end surface 71 of the tip portion 70 of the insertion member 7 is arranged at a predetermined position in the space 560, the pressing is stopped. The predetermined position is obtained by dividing the remaining volume obtained by subtracting the volume of the insertion member 7 from the volume of the space 560 by the flat area of the space 560. At the end of pressing, the region from the inner bottom surface of the bottom portion 51 of the case 5 to the end face 71 is the first region 561.

Specifically, the insertion member 7 is moved to the bottom 51 side of the case 5 in the space 560, and the end surface 71 of the tip 70 is brought into contact with the liquid surface of the raw material resin 600 (FIG. 5). In this example, since the area S ₇ of the end face 71 includes a portion equal to or larger than the flat area of the space 560, the insertion member 7 is elastically deformed and moved toward the raw material resin 600. The insertion member 7 is inserted into the bottom 51 side while rubbing against the outer peripheral surface 100 of the union body 10 and the first surface 521 of the case 5.

When the insertion member 7 comes into contact with the raw material resin 600, the insertion member 7 is further pressed toward the bottom 51 side of the case 5 as shown by the white arrow in FIG. The raw material resin 600 pressed against the bottom 51 side of the case 5 flows from the space 560 toward the second region 562 and further toward the opening side of the case 5, as shown by the black arrow in FIG. Even when the distance between the outer peripheral surface 100 of the union body 10 and the inner peripheral surface 520 of the case 5 in the second region 562 is narrow, the raw material resin 600 can enter the narrow portion by being pressed by the insertion member 7. In other words, the space 560 functions like a cylinder and the insertion member 7 functions like a piston, so that the raw material resin 600 is pressure-filled from the space 560 to the second region 562.

In this example, as described above, since the flat area S _max of the space 560 ≤ the area S ₇ of the insertion member 7, the insertion member 7 brings the filling portion of the raw material resin 600 in the space 560 into a state close to liquid tightness. Become. For this reason as well, the raw material resin 600 pressed from the insertion member 7 easily enters the above-mentioned narrow portion of the second region 562. Further, the raw material resin 600 easily enters the gap between the union body 10 and the insertion member 7.

In this example, in the insertion member 7 pushed into the space 560, the tip portion 70 is sandwiched between the holding member 4 on the bottom 51 side of the case 5 and the first surface 521 of the case 5. Further, the end portion on the end surface 72 side is sandwiched between the holding member 4 on the opening side of the case 5 and the first surface 521 of the case 5. As a result, the insertion member 7 is positioned in the case 5.

The union body 10 is covered with the raw material resin 600 that has flowed into the second region 562. In this example, the raw material resin 600 covers the opening-side surface of the case 5 in the union body 10 and the insertion member 7 as described above. In at least one of the union body 10 and the insertion member 7, the opening-side surface of the case 5 may be exposed from the raw material resin 600.

By solidifying the raw material resin 600, the sealing resin portion 6 is formed. The raw material resin 600 filled between the insertion member 7 pushed into the space 560 and the bottom portion 51 of the case 5 constitutes the first resin portion 61 after solidification. The raw material resin 600 filled in the second region 562 constitutes the second resin portion 62 after solidification.

(Use)
The reactor 1 of the first embodiment can be used as a component of a circuit that performs a voltage step-up operation or a voltage step-down operation. For example, the reactor 1 can be used as a component of various converters and power conversion devices. Examples of converters include in-vehicle converters, air conditioner converters, and the like. The in-vehicle converter is typically a DC-DC converter. Examples of vehicles equipped with a converter include hybrid vehicles, plug-in hybrid vehicles, electric vehicles, fuel cell vehicles, and the like.

(Main actions / effects)
Since the reactor 1 of the first embodiment includes the insertion member 7, the filling amount of the sealing resin portion 6 is smaller than that in the case where the insertion member 7 is not provided. Further, the reactor 1 of the first embodiment is excellent in heat dissipation because the heat of the combined body 10 is transferred to the case 5 by the sealing resin portion 6, particularly the second resin portion 62.

Since the volume of the insertion member 7 of this example is large as shown below, the filling amount of the sealing resin portion 6 may be small. The insertion member 7 of this example has a rectangular parallelepiped shape, the length H ₇ is 40% or more of the depth H _{5 of the case 5, and the area S 7} is the flat area S _max or more of the space 560. The volume of the member 7 is approximately an area S ₇ × a length H ₇ . It can be said that such an insertion member 7 has a large volume. Further, in this example, since the corners of the space 560 are rounded, the filling amount may be smaller than that in the case of being square.

The reactor 1 of this example has excellent heat dissipation from the following four points.
(A) The region of the winding portions 21 and 22 facing the inner peripheral surface 520 of the case 5 is larger than that of the storage form of the modified example 3 described later.
(B) The second resin portion 62 is filled between the winding portions 21 and 22 and the inner peripheral surface 520 of the case 5, and the heat of the winding portions 21 and 22 is transferred to the case 5 by the second resin portion 62. Is well communicated to.
(C) The sealing resin portion 6 contains a powder made of a non-metallic inorganic material and has excellent thermal conductivity.
Spacing narrow space between the inner circumferential surface 520 of the outer circumferential surface 100 and the case 5 of (d) combined product 10, where there are many places having a thickness t ₆ primarily. Specifically, the region of 80% or more of the circumference of the union body 10 corresponds to the narrow portion.

Further, the reactor 1 of the first embodiment is excellent in manufacturability in that the filling time of the raw material resin 600 of the sealing resin portion 6 can be shortened. In addition, the manufacturing cost can be reduced.

There are three reasons why the filling time is short.
(A) The filling amount of the raw material resin 600 may be as small as the volume of the insertion member 7.
(B) The space 560 where the raw material resin 600 is filled is a relatively large space.
The insertion member 7 can press the raw material resin 600 filled in the space 560.

(B) Regarding the size of the space 560, the length L ₇ of the space 560 of this example is the distance between the outer peripheral surface 100 of the union body 10 and the inner peripheral surface 520 of the case 5 in the second region 562, here the thickness. Greater than t _{6 (t 6} << L ₇ ). Therefore, as compared with the case where the thickness t ₆ about the narrowest point of the filling starting point of the starting resin 600, a short filling time. Further, in this example, the nozzle 9 can be arranged in the space 560, and the nozzle 9 can be used, so that the filling time tends to be shortened. Further, as described above, the tip of the nozzle 9 is arranged on the bottom 51 side of the case 5, the nozzle 9 is unevenly distributed on one end side of the case 5 in the long side direction, and the one-point casting is performed. Entrainment of air bubbles can be effectively prevented. As a result, the filling time including the degassing time tends to be shortened.

(C) Regarding pressing, in this example, even if there is a narrow portion such as 1 mm or less in the second region 562 as described above, the pressed raw material resin 600 can enter the narrow portion. Further, in this example, even if the raw material resin 600 contains a powder made of a non-metallic inorganic material and has a high viscosity, the pressed raw material resin 600 can enter the narrow portion. Further, in this example, since the constituent material of the tip portion 70 is rubber and the flat area S _max ≤ area S ₇ allows the above-mentioned liquid-tight state to be constructed, the insertion member 7 applies a pressing force to the raw material resin. It can be surely given to 600. From this as well, the pressed raw material resin 600 can enter the narrow portion.

The reactor 1 of this example is excellent in manufacturability from the following three points.
-The insertion member 7 is excellent in manufacturability. The reason for this is that the insertion member 7 is an integrally molded product made of a single material, and has a simple shape in which the cross-sectional shape and the cross-sectional area are uniform in the axial direction of the insertion member 7. Typically, the insertion member 7 is manufactured by cutting a long columnar material or rod-shaped material to a predetermined length.
-The insertion member 7 prevents the union body 10 from being displaced in the case 5. Therefore, it is not necessary to separately arrange a member for positioning the union body 10 when filling or solidifying the raw material resin 600.
-Case 5 is excellent in manufacturability. In the case described in Patent Document 1, it is necessary to process the introduction path of the raw material resin in the case itself. In the reactor 1 of this example, the processing of the above case is unnecessary.

The reactor 1 of this example is small from the following three points.
The distance between the union body 10 and the case 5 in the second region 562 can be set to, for example, 1 mm or less. In this respect, the case 5 tends to be small.
A space 560 in which the insertion member 7 is arranged is provided only on one end side of the case 5 in the long side direction. _{In such a case 5, the length L 5} of the case 5 tends to be shorter than, for example, when the insertion members 7 are arranged on both sides in the long side direction. Further, in the case 5 of this example, the length in the short side direction is shorter than that in the case where the insertion member 7 is arranged on one end side or both sides in the short side direction, for example. In these respects, the case 5 tends to be small.
The length of the case 5 in the union 10 along the above-mentioned short side direction <the length L ₁₀ of the union 10 <height H ₁₀ . Therefore, the area of the bottom portion 51 of the case 5 is smaller than that of the storage form of the modified example 3 described later. The area of the bottom portion 51 is generally the product of the length along the short side direction and the length L _{10 of the union body 10.}

In addition, in the reactor 1 of the first embodiment, the volume of the first resin portion 61 can be reduced by the insertion member 7. Therefore, when the temperature becomes high when the reactor 1 is used, the amount of thermal expansion of the first resin portion 61 tends to be small. Therefore, as compared with the case where the sealing resin portion 6 is substantially entirely filled in the space 560, the sealing resin portion 6, particularly the first resin portion 61, is less likely to be cracked due to its thermal expansion.

The present invention is not limited to these examples, and is indicated by the scope of claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.
For example, at least one of the following changes can be made to the reactor 1 of the first embodiment.

(Modification 1) The insertion member 7 satisfies at least one of the following configurations (1) to (3).
(1) Hereinafter, a modified example of the insertion member 7 will be described with reference to FIG.
The insertion member 7 of the modified example 1 (1) includes a tip portion 70 and a shaft portion 75. The constituent materials of the tip portion 70 and the shaft portion 75 have a type A durometer hardness of 50 or more.

The tip portion 70 is a portion arranged on the bottom portion 51 side of the case 5, and has an end face 71. The shaft portion 75 is a portion arranged on the opening side of the case 5, and has an end face 72. The tip portion 70 and the shaft portion 75 are connected and used as an integral member.

The tip portion 70 of this example has a rectangular parallelepiped shape substantially corresponding to the shape of the space 560, and the area S ₇ of the end face 71 is equal to or larger than the flat area S _{max of the space 560.} The constituent material of the tip portion 70 is a rubber having a type A durometer hardness of 90 or less. The length _{H 70} of the tip 70 may be appropriately selected. In this example, the length H _{70 is 10% or more and 40% or less of the length H 7} of the insertion member 7, and is shorter than the length of the shaft portion 75. The length H ₇₀ is the length of the insertion member 7 along the axial direction.

The tip portion 70 of this example has a stepped shape in which the cross-sectional areas cut in a plane orthogonal to the axial direction of the insertion member 7 are partially different. In this example, the end face 71 and its vicinity, the central portion and its vicinity in the axial direction, and the surface of the tip portion 70 opposite to the end face 71 and its vicinity have flange portions. The area of the contour of the flange portion has an area S _7. Portion other than the flange at the distal end 70 is smaller than the area S _7.

The shaft portion 75 of this example is a round bar-shaped member. The shaft portion 75 has a uniform cross-sectional shape and cross-sectional area cut in a plane orthogonal to the axial direction of the insertion member 7 in the axial direction. The flat area and the cross-sectional area of the shaft portion 75 of this example are _{less than the flat area S max} and smaller than _{the area S 7} of the end face 71. Further, the flat area of the shaft portion 75 and the cross-sectional area thereof are smaller than the cross-sectional area of the tip portion 70 other than the flange portion. The constituent material of the shaft portion 75 of this example is a resin, for example, a PPS resin. Further, the hardness of the constituent material of the shaft portion 75 is higher than the hardness of the constituent material of the tip portion 70.

The insertion member 7 of the modification 1 (1) can reduce the friction when inserting the insertion member 7 into the space 560 while being able to construct the above-mentioned liquid-tight state by the tip portion 70 as described above. The reason for this is that _{the length of the portion of the insertion member 7 having the flat area S max} ≤ area S ₇ is shorter than that of the insertion member 7 described in the first embodiment, and the outer peripheral surface 100 of the union body 10 and the inner peripheral surface of the case 5 are formed. This is because the contact area with the 520 is small. In this example, only a part of the tip portion 70 is in contact with the outer peripheral surface 100 of the union body 10 and the inner peripheral surface 520 of the case 5, and the remaining portion of the tip portion 70 and the shaft portion 75 are the outer peripheral surface 100 and the inner peripheral surface 520. Substantially not in contact with.

Further, the insertion member 7 of the modified example 1 (1) can more reliably press the tip portion 70 while being able to construct the liquid-tight state. The reason for this is that the hardness of the constituent material of the shaft portion 75 is higher than the hardness of the constituent material of the tip portion 70 and the rigidity is excellent.

In addition, the insertion member 7 of the modified example 1 (1) also functions as a positioning member of the union body 10 in the case 5. Since this reason, even if the plane area of the shaft portion 75 is smaller than the area S _7, the inner peripheral surface 520 of the outer circumferential surface 100 and the case 5 of the tip portion 70 is combined product 10, where it closely on the first surface 521 is there.

The constituent material of the tip portion 70 and the constituent material of the shaft portion 75 may be the same. In this case, since the insertion member 7 can be an integrally molded product made of a single material, it is excellent in manufacturability. Further, the flat area and the cross-sectional area of the shaft portion 75 may be _{equal to or larger than the flat area S max of the space 560.} Further, the shape of the shaft portion 75 may be similar to that of the tip portion 70. As described above, in the insertion member 7 including the tip portion 70 and the shaft portion 75, the degree of freedom of the constituent material, the degree of freedom of the shape, and the degree of freedom of the size are high.

(2) The insertion member 7 includes a portion where at least one of the cross-sectional shape and the cross-sectional area cut in a plane orthogonal to the axial direction is different.
As an example of such an insertion member 7, a member having a portion having a locally different cross-sectional area as in the modified example 1 (1) can be mentioned. As another example, a tapered columnar shape or a tapered column whose cross-sectional area gradually or gradually decreases from the end face 72 arranged on the opening side of the case 5 toward the end face 71 arranged on the bottom 51 side of the case 5. Examples include rod-shaped members.

(3) The number of insertion members 7 is plural.
In this case, the constituent materials of each insertion member 7 may be the same or different. For example, the insertion member 7 made of an electrically insulating material and the insertion member 7 made of a conductive material may be included.
Further, in this case, the arrangement position of each insertion member 7 does not matter as long as it is lined up with the union body 10. For example, a plurality of insertion members 7 are located on one end side of the case 5 in the long side direction and are arranged along the short side direction. Alternatively, a plurality of insertion members 7 may be arranged separately on both sides in the long side direction. Alternatively, there may be an insertion member 7 arranged on one end side in the long side direction of the case 5 and an insertion member 7 arranged on one end side in the short side direction. As a specific example of this, the former insertion member 7 is the insertion member 7 described in the first embodiment, and the latter insertion member 7 is, for example, a plate-shaped insertion member arranged along the third surface 523 of the case 5. It can be mentioned that it is 7. The insertion member 7 described in the first embodiment and the plate-shaped insertion member 7 are arranged in an L shape in the case 5. The size of each insertion member 7 is adjusted so that the ends do not interfere with each other.

(Modification 2) The sealing resin portion 6 does not embed both the union body 10 and the insertion member 7, but exposes one or a part of both of the union body 10 and the insertion member 7.
In the modified example 2, the filling amount of the sealing resin portion 6 can be further reduced, and the filling time can be shortened. For example, when a part of the union body 10 is exposed from the sealing resin portion 6, the second resin portion 62 is at least between the outer peripheral surface of the winding portions 21 and 22 and the inner peripheral surface 520 of the case 5. When it is filled and covers the outer peripheral surfaces of the wound portions 21 and 22, it is preferable because it has excellent heat dissipation and insulating properties.

(Modification 3) The storage state in the case 5 in the union body 10 is the following (1) or (2).
(1) In a state where the union body 10 is housed in the case 5, the axial direction of the winding portions 21 and 22 is orthogonal to the depth direction of the case 5, and the axis of the winding portions 21 and 22 has the above depth. Placed in the same position in the direction. This storage state is the storage state described in Patent Document 1.
(2) In a state where the union body 10 is housed in the case 5, the axial direction of the winding portions 21 and 22 is orthogonal to the depth direction of the case 5, and the axis of the winding portions 21 and 22 has the above depth. Line up in the direction.
In each of the storage forms, the outer core portions 33 of the union body 10 are arranged close to each other on both sides of the case 5 in the long side direction. Typically, the insertion member 7 is arranged along the outer core portion 33 or along the holding member 4 that covers the outer core portion 33.

(Modification 4) The coil 2 satisfies at least one of the following configurations (1) to (5).
(1) The winding portions 21 and 22 are composed of different windings.
In this case, the connecting portion may be in a form in which the ends of the windings to which the external device is not connected are directly connected by welding, crimping, or the like, or in a form in which they are indirectly connected by metal fittings.
(2) The winding is a wire rod other than the coated flat wire, for example, a coated round wire having a circular cross-sectional shape.
(3) The shape of the winding portions 21 and 22 is a shape other than a square cylinder, for example, a cylindrical shape.
(4) Specifications are different between the winding portions 21 and 22.
(5) The number of winding parts is one.

(Modification 5) The magnetic core 3 satisfies at least one of the following configurations (1) to (5).
(1) The number of core pieces constituting the magnetic core 3 is one, two, three, or five or more.
(2) The magnetic core 3 includes a core piece having a portion arranged inside the winding portion of the coil 2 and a portion arranged outside the winding portion. Examples of such a core piece include a U-shaped core piece, an L-shaped core piece, an E-shaped core piece, and the like.
(3) At least one of the inner core portions 31 and 32 is composed of a plurality of core pieces instead of one core piece. In this case, there may be a magnetic gap between adjacent core pieces.
(4) The outer peripheral shape of the inner core portions 31 and 32 is not similar to the inner peripheral shape of the wound portions 21 and 22. For example, the winding portion 21 has a square tubular shape, and the inner core portion 31 has a columnar shape.
(5) The corners of the core piece are chamfered. The chamfered core piece has excellent strength because the corners are not easily chipped.

(Modification 6) The reactor 1 includes an adhesive layer (not shown) between the union body 10 and the inner bottom surface of the bottom portion 51 of the case 5.

(Modification 7) The reactor 1 does not include one or both of the resin mold portion 8 and the holding member 4.

1 reactor, 10 union, 100 outer peripheral surface 2 coil, 21 and 22 winding part 3 magnetic core, 31, 32 inner core part, 33 outer core part 4 holding member, 43 peripheral wall 5 case, 51 bottom, 52 side wall part 520 Inner peripheral surface, 521 1st surface, 522 2nd surface 523 3rd surface, 524 4th surface 560 Space, 561 1st area, 562 2nd area 6 Encapsulating resin part, 61 1st resin part, 62 2nd resin Part, 600 Raw material resin 7 Insert member, 70 Tip part, 71, 72 End face, 701, 705 Side surface 8 Resin mold part, 81, 82 Inner resin part, 83 Outer resin part 9 Nozzle H ₅ Depth, H ₆ , H ₁₀ Height, H ₇ , H ₇₀ Length, t ₆ Thickness L ₅ , L ₇ , L ₁₀ Length

Claims (5)

A combination containing a coil and a magnetic core,
The case where the union is stored and
An insertion member that is stored side by side with the union in the case,
It is provided with a sealing resin portion to be filled in the case.
The case includes a bottom and a side wall.
The insertion member comprises a tip that is spaced apart from the bottom.
The space formed by the union, the insertion member, and the case includes a first region provided between the bottom portion and the tip portion, and a second region other than the first region.
The sealing resin portion includes a first resin portion filled in the first region and a second resin portion filled in at least a part of the second region.
The constituent material of the insertion member has a type A durometer hardness of 50 or more.
Reactor. The reactor according to claim 1, wherein the constituent material includes resin or rubber. The constituent material of the tip portion is the rubber.
The tip portion includes an end face in contact with the first resin portion.
The reactor according to claim 2, wherein the area of the end face is equal to or larger than the maximum flat area of the first region in a state where the tip portion is not elastically deformed. The reactor according to any one of claims 1 to 3, wherein the length of the insertion member along the depth direction of the case is 40% or more of the depth of the case. The reactor according to any one of claims 1 to 4, wherein the constituent material of the sealing resin portion includes a resin and a powder made of a non-metallic inorganic material.

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